Unitary folding box



y 1955 R. VAN ROSEN ET AL 2,756,920

UNITARY FOLDING BOX Filed Dec. 24, 1951 3 Sheets-Sheet 1 M s5 l INVENTORS ROBERT VAN ROSEN, GEORGE EARENS 6| GLENN E. STRUBLE AT TORNEYS July 31, 1956 R. VAN ROSEN ETAL UNITARY FOLDING BOX 5 Sheets-Sheet 2 Filed Dec. 24, 1951 8 Raw E N U E N E R V T N AS I T F. 7 R E E ORN. R E L G G M ID 0 5 VI H 2 B ATTORNEYS July 31, 1956 R. VAN ROSEN ET AL UNITARY FOLDING BOX 3 Sheets-Sheet 3 Filed Dec. 24, 1951 INVENTORS ROBERT VAN ROSEN,

GEORGE EARENS a GLENN E. STRUBLE BY ATTORNEYS United States Patent UNITARY FOLDING BOX Robert Van Rosen, Hamilton, George F. Arens, St.

Bernard, and Glenn E. Struble, Hamilton, Ohio, assignors to The Gardner Board and Carton Company, Middletown, Ohio, a corporation of Ohio Application December 24, 1951, Serial No. 263,026 7 Claims. (Cl. 229--3'1) This invention relates to folding boxes or cartons which are formed from a single flat blank and adapted to be set up at the time of use.

It is the principal object of the invention to provide a box of this character which is simple and easy to manufacture being blanked out from a single fiat piece of material, partially scored, cut and folded so that it may be shipped in flat form, adapted for ready setting up by the user, and in its set up condition providing a box which has an open portion on its top so that the contents are displayed, but which has limited top walls at its ends affording a sturdy and stiff construction so as to afford proper protection for the contents of the box.

It is also an object to provide such a box, specially adapted for the packaging of fragile articles such as cut flowers and the like, which has an open appearance for viewing the contents, while at the same time being secure and firm so as to afford adequate support and protection for the contents.

Other objects and advantages will be apparent from the following description, in the accompanying drawings and the appended claims.

In the drawings- Fig. 1 is a plan view of the blank for forming the box showing the pattern of cut and score lines;

Fig. 2 is a plan view of the blank with the side wall panels folded and secured upon themselves and showing the form in which the finished blank may be shipped in flat condition;

Fig. 3 is a view looking down upon the box during an intermediate step in the setting up thereof;

Fig. 4 is a view in perspective looking toward one end of the box showing steps in the assembly of the end wall;

Figs. 5 and 6 are similar views showing thenext and final step in the erection of the box;

Fig. 7 is a vertical sectional view through the end of the box in its erected condition on the line 7--7 of Fig. 6;

Fig. 8 is a plan view showing a modified form of blank for forming the box, employing a difierent form of corner closing means;

Figs. 9 and 10 show succeeding steps in the setting up of this form of box; and

Fig. 11 is a vertical sectional view through the end of the box on the line 1111 of Fig. 10.

Referring to the drawings which disclose preferred embodiments of the invention, the blank is shown generally at 10 in Fig. 1 and is formed with a bottom panel extensions 28, have integral "ice with a double notch pattern comprising an upper outer notch 20 the material from which is removed, and a lower inner notch 21 with the material forming the same remaining integrally attached to the outer wall panels 13 to form tabs 22. It will be seen that this double notched arrangement is formed along the upper outer corners of each corner wall panel, and when the side walls are folded in the form shown in Fig. 2 the tabs 22 are left projecting outwardly substantially as shown. When the side walls are raised these tabs 22 may be folded inwardly at the top of the side walls as shown in Fig. 3.

End wall panels 25 are formed integrally and separately from the bottom panel by score lines 26. Each end wall panel has double extensions 27 and 28 defined by score lines 29 and 30 respectively, formed integrally therewith and projecting outwardly therefrom. The outer such flaps 32 formed thereon and defined by score lines 33.

Means are provided for closing the corners of the box and in the form shown in Figs. 1 through 7, such means are .in the form of gussets which have score lines 35 extending therethrough .in a diagonal direction forming two portions 36a and 36b of the gusset integrally attached one to the adjacent side wall 13 and the other to the adjacent end wall 25 along score lines 37 and 38 respectively. The score line 35 of the gusset extends in such position that the height of portion 36b will be greater than that of portion 36a when folded in the erected position of the box.

In order to erect the box to its usable position, the flat blank in the form shown in Fig. 2 is first folded to raise the double side walls to a vertical position, as shown in Fig. 3. This operation also tends to raise the gusset portion 36. The next step, as shown in Fig. 4, is to raise the end wall and to fold the two gusset portions upon themselves, with the front or inner gusset wall 36a extending to a lesser height than the outer or rear gusset wall 36b. The side tab portion 22 should likewise fold inwardly to a horizontal position as shown by the right hand tab in Fig. 4.

In order to form the top wall and to lock the box in its usable position, the double extension portions 27 and 28 are next folded downwardly as shown in Fig. 5 about score line 29 leaving the flaps 32 folded in a backward direction, this fold taking place practically automatically as the double extension walls are folded into position. It will be observed in this operation that the inner extension 27 falls above and overlies the two tabs 22. The outer extension 28 is then folded back upon itself along the score line 30, so that it extends below tabs 22 which are thereby received between and held in locking engagement with this double wall top construction.

11 which is separated by score line 12 from the double side wall panels 13 and 14, integrally formed and separated from each other by score lines 15. In the form of box illustrated the outer side wall panels 14 are intended to be folded inwardly, as shown in Fig. 2, and secured in such position by suitable means such as the adhesive indicated at 16. If desired the outer panels 14 may be folded in the opposite direction, and similarly secured to form the double wall side panels. The side wall panel which forms the inner wall of the box in the folded condition, i. e., panels 14 in the form shown, are notched Likewise, in the final folding movement, the flaps 32 are brought into position where they fold into the notches 21, the dimensions being such that the flaps just fit into this square notched out area. The lower notch 20 forms a finger access by means of which the flap 32 may be engaged to withdraw it from the locking engagement but until so withdrawn, they fit closely and firmly within the notch to retain the box securely in its erected condition.

Simultaneously, the edge 39 of the outer extension 2h fits upon the edge of the forward gusset 36a and against the face of the rear gusset 36b as shown in Fig. 7, to both lock the extension into position and to further stabilize and secure the entire box construction. The edge 39 maybe straight or suitably contoured if so desired to further increase its interlocking engagement with the walls of the gussets.

Inthe form of box shown in Figs. 8 through 11, the same parts are shown by similar reference'numerals, the means for closing the corners being of different construction and comprising locking 'flaps 40 with notches 41 formed therein in such manner that when the side walls are erected as shown in Fig. 9, the two notches of the flaps at the same end of the box can be hooked over each other to lock together, thereby retaining the side walls in an erect position and closing the corners of the box.

Also, as shown, the side edges of the corner closure flaps are provided with projections 42 on the side adjacent the notch and with projection 43 on the side opposite the notch so that when erected as shown in Fig, 9 there will be two pairs of such projections spaced from each other. A corresponding pattern of notches 44 is provided on the edge of the outer extension panels 28, defining ribs 45, and it will be evident from Figs. 9, 10 and 11 that this edge is adapted to interlock with the projections 42, 43 when folded into final position such as shown in Fig. 11. This further stiffens and strengthens the box and assures that it will stand up properly when in use.

The invention thus provides a simple easily manufactured blank which may be shipped in a flat condition and which may be readily assembled by the user without use of tools or special equipment of any kind. When so erected, the box has the major portion of its top free and open for access or for viewing the contents as may be desired and nevertheless is firmly and securely formed so that the entire box is closed and of stiff and firm construction. The actual extent of the top which is open may be such as desired but preferably it is open along the major part of the length of the box. Its construction is firm and secure however, and the box may be shipped with the assurance of providing adequate protection for the contents of the box at all times. When desired it may be disassembled and collapsed for re-shipment or re-use.

While the methods and articles herein described constitute a preferred embodiment of the invention, it is to be understood that the invention is not limited to these precise methods and articles, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.

What is claimed is:

l. A collapsible box formed from a unitary fiat blank and having a bottom panel, inner and outer side wall panels with the inner panel folded inwardly upon the outer panel and secured in face to face contact therewith, the inner wall panels having notches adjacent their upper corners forming shallow recesses, end walls, pleated folding portions joining said outer side wall panels and said end walls to close the corners of said box, the part of said pleated portion joined to said end wall being of greater height than the portion joined to said outer side wall panel in the erected condition of the box, inner and outer extension panels on each said end wall and adapted to be folded upon each other at the top of said side wall panels in the erected condition, and locking flaps on the outer of said extension panels adapted to be received in said shallow recesses of said side wall panels to retain the box in its erected condition, said outer extension panels in the erected condition fitting above the edge of the shorter of said pleated portions and against the face of the longer of said pleated portions.

2. A collapsible box formed from a unitary flat blank and having a bottom panel, inner and outer side wall panels folded flat upon and secured to each other, the inner wall panels having notches adjacent their upper corners and the notched out material forming tabs adapted to extend inwardly at the upper edge of said side walls, end walls, inner and outer extension panels extending from each said end wall and adapted to be folded upon each other at the top of said side wall panels in the erected condition of the box, and with said tabs received therebetween, and locking flaps on the outer of said ex tension panels adapted to be received in the notches of the inner side wall panels in abutting contact with the outer side wall panels to retain the box in its erected condition.

3. A collapsible box formed from a unitary flat blank and having a bottom panel, inner and outer side wall panels secured in face to face contact with each other, the inner wall panels having notched out portions adjacent their upper corners and the notched out material forming tabs secured along the upper edges of said side Walls, end walls, means for closing the corners of said box, inner and Outer extension panels on each said end wall and adapted to be folded upon each other at the top of said side wall panels in the erected condition of said box, said tabs being received in interfitting relation between said inner and outer extension panels when folded upon each other in the erected condition, and locking flaps on the outer of said extension panels adapted to be received in the notches of the inner side wall panels in abutting contact with the outer side wall panels to retain the box in its erected condition.

4. A folding box made from a single piece flat blank comprising a bottom panel, side wall panels integral with said bottom panel folded flat upon themselves and forming inner and outer double thickness walls, the upper ends of said inner side wall panels being notched with a double notch pattern one of which is offset outwardly of and below the other, the material of said notches forming integral tabs adapted to extend inwardly of said box in the erected position thereof, end wall panels integral with said bottom panel, double extension panels on said end wall panels adapted to be folded upon each other with said tabs therebetween to form a double wall top extending inwardly from the ends of the box over a part of the length thereof, means on said panels for closing the corners of the box in the erected position thereof, and flaps on one of said end wall extension panels adapted to be folded downwardly and received in locking relation in the upper of said notches of said inner side wall panels and in abutting relation with said outer side wall panels for locking the box in its erected position.

5. A folding box made from a single piece flat blank comprising a bottom panel, side wall panels integral with said bottom panel folded flat upon themselves and forming inner and outer double thickness walls, the upper ends of said inner side wall panels being notched with a double notch pattern one of which is offset outwardly of and below the other, the material of said notches forming integral tabs adapted to extend inwardly of said box in the erected position thereof, end wall panels integral with said bottom panel, double extension panels on said end wall panels adapted to be folded upon each other with said tabs therebetween to form a double wall top extending inwardly from the ends of the box over a part of the length thereof, means on said panels for closing the corners of the box in the erected position thereof, the inner top wall portion of said box having interlocking engagement over said corner forming means, and flaps on one of said end wall extension panels adapted to be folded downwardly and received in locking relation in the upper of said notches of said inner side wall panels and in abutting relation with said outer side wall panels for locking the box in its erected position.

6. A folding box made from a single piece fiat blank comprising a bottom panel, inner and outer side wall panels integrally joined and secured in face to face contact with each other, the upper outer corners of the inner wall panels having notches formed therein with the notched out material forming integral tabs upon said outer side wall panels, end wall panels, double extension panels extending outwardly from said end walls and adapted to be folded upon themselves with said tabs received in interlocking relation therebetween, means for closing the cor ners of said box, and flaps on said end wall extensions adapted to interlock in said notches of said inner side wall panels and in abutting relation with said outer side Wall panels in the erected condition of said box.

7. A folding box made from a single piece blank comprising a bottom panel, inner and outer side wall panels integrally joined and secured in face to face contact with each other, the upper outer corners of the inner References Cited in the file of this patent wall panels having notches formed therein, 1 end Wal UNITED STATES PATENTS panels, double extensions projecting outward y beyon said end wall panels and adapted to be folded upon each 5 Lal?mbarde July 1933 other to form a double thickness top wall of limited ex- 5 30,602 Smlth Sept 1938 tent in relation to the length of the box, the outer edge of 2218360 Rokol 1940 said end wall extension having a contoured surface there- 2313376 Unman 1943 on, means for closing the corners of said box adapted to 2388243 Ames9n 1945 lie inwardly 0f the end wall of the box in the erected 2450035 De Mlan Sept 1948 condition thereof, said double extension being folded upon 10 FOREIGN PATENTS itself with said flaps fitting into and locking Within said 105,907 Australia Dec 1, 1938 notches of said inner side wall panels and in abutting relation with said outer side wall panels and with said contoured edge of said extension panel interlocking with the upper edge of said corner closure means. 15 

